Integrated circuit and method of manufacturing the same

ABSTRACT

Presented is an integrated circuit packaged at the wafer level wafer (also referred to as a wafer level chip scale package, WLCSP), and a method of manufacturing the same. The WLCSP comprises a die having an electrically conductive redistribution layer, RDL, formed above the upper surface of the die, the RDL defining a signal routing circuit. The method comprises the steps of: depositing the electrically conductive RDL so as to form an electrically conductive ring surrounding the signal routing circuit; and coating the side and lower surfaces of the die with an electrically conductive shielding material.

This invention relates to the field of integrated circuit, and moreparticularly to packaging an integrated circuit at the wafer level.

An integrated circuit packaged at the wafer level is referred to as aWafer Level Chip Scale Package (WLCSP). This differs from thetraditional process of assembling individual units in packages afterdicing them from a wafer. This WLCSP process is an extension of waferFab processes, where the device interconnects and protection areaccomplished using the traditional fab processes and tools. In the finalform, a WLCSP device is essentially a die with an array pattern of bumpsor solder balls attached at an I/O pitch that is compatible withtraditional circuit board assembly processes.

WLCSP can be considered as a chip-scale packaging (CSP) technology,since the resulting package is of the same size as the die. WLCSPtechnology differs from other ball-grid array (BGA) and laminate-basedCSPs in that no bond wires or interposer connections are required.

The key advantages of the WLCSP is the die to PCB inductance isminimized, reduced package size, and enhanced thermal conductioncharacteristics.

Critical components are required to meet Electromagnetic Compatibility(EMC) standards and/or be shielded from Electromagnetic interference(EMI) and Electrostatic Discharge (ESD). Typically this is done usingmetal caps that act as a Faraday Cage (i.e. a metallic enclosure thatprevents the entry or escape of an electromagnetic field). However, thecontinual need to reduce the size of integrated circuit means thatconventional shielding approaches (such as those employing metal caps)are not suitable.

It is known to employ die embedding for the purpose of EM shielding,which enables a critical device to be capped and reduces the requiredboard area compared to conventional types of protection. However, thisdie embedding technique requires the wafers to be shipped to an externalboard manufacture, thus breaking the manufacturing flow.

According to an aspect of the invention there is provided a method ofmanufacturing a wafer level chip scale package, WLCSP, comprising a diehaving an electrically conductive redistribution layer, RDL, formedabove the upper surface of the die, the RDL defining a signal routingcircuit, wherein the method comprises the steps of: depositing theelectrically conductive RDL so as to form an electrically conductivering surrounding the signal routing circuit; and coating the side andlower surfaces of the die with an electrically conductive shieldingmaterial, wherein the electrically conductive shielding materialcontacts at least a portion of the periphery of the conductive ring.

Thus, there is proposed is a method of manufacture that provides EMIand/or ESD protection through the provision of conductive materialaround the die without a resultant size increase or the use ofnon-semiconductor processes. The costs of such a manufacturing processare typically lower than alternative methods that may require separatenon-semiconductor processes.

According to another aspect of the invention there is provided a WLCSPcomprising a die having an electrically conductive redistribution layer,RDL, formed above the upper surface of the die, the RDL defining asignal routing circuit, wherein the electrically conductive RDL forms anelectrically conductive ring surrounding the signal routing circuit, andwherein the side and lower surfaces of the die are coated with anelectrically conductive shielding material such that the electricallyconductive shielding material contacts at least a portion of theperiphery of the conductive ring

Embodiments may employ electroless (E-less) plating after formation ofthe electrically conductive redistribution layer into an electricallyconductive ring encircling a circuit of the die. This provides a contactring around the die for connection of the ground plane (on top of die)to side and back-side plating of the die, thereby providing maximum EMshielding. Also, associated costs may be reduced, since existing E-lessplating techniques and material may be used.

The corners of the die may also be e-less plated, due to the fact thatthe dies are completely separated, whereas conventional embeddedapproaches require the dies to be held together at the corners(therefore preventing plating of the die corners). Embodiments thusprovide a shielding arrangement that covers the sides, corners, andbackside of a WLCSP.

Further, the size of a WLCSP according to the invention may be nearlythe same as a conventional non-shielded WLCSP. In other words, a WLCSPaccording to the invention may only be larger than a conventional WLCPby the thickness of the electrically conductive shielding material.

Examples of the invention will now be described in detail with referenceto the accompanying drawings, in which:

FIG. 1 is a cross-sectional representation of a conventional typicalWLCSP;

FIG. 2 is a flow diagram of a conventional WLCSP process formanufacturing the WLCSP package of FIG. 1;

FIGS. 3A-3B illustrate the etching of a grid pattern in a waferaccording to an example embodiment;

FIGS. 4A-4B illustrate the top surface of a die prepared for receptionof a metal RDL according to an example embodiment;

FIGS. 5A-5B illustrate the die wafer plated with copper according to anexample embodiment;

FIGS. 6A-6B illustrate the mounting of the die wafer for sawing ansingulation according to an example embodiment;

FIGS. 7A-7B illustrate the sawed and singulated die according to anexample embodiment;

FIG. 8 illustrate the separated die flipped on top of UV/Heat-curableglue layer which is printed on a sheet of glass according to an exampleembodiment;

FIGS. 9A-9B illustrate a reconfigured wafer of dies according to anexample embodiment;

FIGS. 10A-10B illustrate the plating on the back of dies according to anexample embodiment;

FIGS. 11A-11B illustrate the labelling of dies according to an exampleembodiment;

FIGS. 12A-12B illustrate the removal of dies from the glass as shown inFIG. 8; and

FIG. 13 is a flow diagram of a method of manufacturing a WLCSP accordingto an embodiment of the invention.

A cross-sectional representation of a conventional typical WLCSP packagewith Redistribution Layer (RDL) and Under Bump Metallization (UBM) isshown in FIG. 1. Also, a flow diagram of a conventional WLCSP processfor manufacturing the WLCSP package is shown in FIG. 2.

The WLCSP die 10 and passivation layer 11 is coated with a first layerof organic dielectric/polyimide 12 (Step 100). A metal redistributionlayer (RDL) 14 for re-routing the signal path from the die peripheralI/O to a new desired location is then deposited on the first layer oforganic dielectric 12 (Step 110). The RDL metal 14 is coated with asecond dielectric/polyimide layer 16 so as to cover the RDL metal andthen patterned into the solder ball array (Step 120). To preventdiffusion and enable solder wetting, an under-bump metallization (UBM)layer 18 is deposited on the RDL 14 (Step 130). A solder ball 20 formedfrom a lead-free alloy is positioned to contact the UBM layer 18 (Step140). A printed solder or plated or ball drop process can be used forsolder bumps. For some applications, a Cu pillar bump, or an Au bump,iso of the solder bump can be employed. These are typically platedbumps. The lower side of the die 10 is coated with a protective polymerfilm 22 (Step 150). This polymer film 22 provides both a mechanicalcontact and UV light protection to the lower side of the die 10.

It will be understood that the example of FIGS. 1 and 2 in the aboveparagraph demonstrates a WLCSP package formed using a two-layer RDLprocess, wherein the RDL metal layer 14 is between two polyimide layers12 and 16.

Turning now to the figures, an embodiment of the invention will now bedescribed.

Firstly, as shown in FIGS. 3A and 3B, a conventional die wafer 30 isetched to create a grid pattern of trenches 32 in the die wafer 30. Thetrenches 32 are saw lanes for guiding sawing of the die wafer 30 into aplurality of individual dies 34 (later in the manufacturing process).Here, the trenches or saw lanes 32 are 5-20 μm deep and 44 μm wide,depending on the sawing lane width for example. It is noted that thismay be preferable to ensure that there is no passivation over the etchedsaw lanes 32. Next, as shown in FIGS. 4A and 4B, the top surface of thedie 30 is prepared for reception of a metal RDL by forming ground pads36 in the trenches 32 around each die 34, thereby forming a ground ring36 around each die 34 (as shown by the illustration of an enlarged viewof an individual die D on the die wafer in FIG. 4B). Here, the groundring 36 is formed to be 10 μm wide.

As shown in FIGS. 5A and 5B, the die wafer 30 is then plated with Copper(Cu) to form a Cu ring 38 around each die 34.

Turning to FIGS. 6A and 6B, the die wafer 30 is then mounted on sawingtape 40 and sawed along the saw lanes (i.e. trenches) 32 to createindividual, separate dies 34 as shown in FIGS. 7A and 7B. Any suitablesawing method may be employed, such as one-cut sawing or step cut sawingfor example. It is noted that, here, that the sawing process has beencompleted so that each saw has passed through the entire thickness (i.e.vertical extent) of the wafer 30 and into the sawing tape 40. Also, eachsaw is marginally thicker than the lateral separation between adjacentground ring edges, thus meaning that the peripheral edges of the groundrings 36 are contacted by the saw when sawing the wafer. This isillustrated in FIG. 7B by the removal of the outline of the ground rings36, indicating that the edges of the ground rings 36 have been removedby the sawing process. In other words, a ground ring 36 arranged arounda die in the saw lane is touched by the sawing blade, thus resulting inremoval of at least a portion of the periphery of the ground ring 36during sawing. This may help to ensure that the E-less NiPdAu platingcontacts the ground ring 36 when the sides of the die 34 are E-lessplated (detailed below).

Next, the separated dies 34 are flipped over as shown in FIG. 8. Here,the dies are flipped on top of an UV/Heat-curable glue layer which isprinted on a sheet of glass 42 or other suitable carrier for holding thedies during further processing. This enables the pitch (i.e. separationbetween die) to be increased. It also covers the front side (i.e. theoriginally upwardly facing side) of the dies, to avoid processing of thefront side. In this way, a reconfigured wafer of dies 34 can be providedas shown in FIGS. 9A and 9B

As shown in FIGS. 10A and 10B, E-less NiPdAu 44 is then plated (using anE-less plating process) on the side and back of the dies 34 (that arepositioned on the sheet of glass 42). Here, the E-less metal overlapsthe dies 34 so as to cover all sides of the dies (except that in contactwith the glass 42). The now upwardly facing side of the dies 34 (i.e.the backside of a die 34 once flipped back, or the side of the dieopposite to the side contacting the glass 42) are then marked using thelaser-based or ink-jet printing process, so as to provided labelled dies34 as shown in FIGS. 11A and 11B.

Finally, as shown in FIGS. 12A and 12B, the dies 34 are removed from thesheet of glass 42 and placed in JEDEC tray for conventional testing andpacking.

Turning to FIG. 13, there is shown a simplified flow diagram of a methodof manufacturing a WLCSP according to an embodiment of the invention.

Firstly, in step 50, a die wafer is etched to create a grid pattern oftrenches in the die wafer, the pattern of trenches separating individualdies on the wafer. Thus, the etched trenches act as guides for sawing ofthe die wafer into a plurality of individual dies. Next, in step 55, theupper surface of the die is prepared for reception of a metal RDL byforming ground pads in the trenches surrounding each die. The padstherefore form a ground ring encircling each die.

The metal for the RDL is then deposited on the ground pads in step 60.This results in the formation of an electrically conductive ringsurrounding each die.

The die wafer is then mounted on sawing tape and sawn along each of thesaw lanes to create individual, separate dies in step 65. Here, thesawing process is adapted to remove at least a portion of the peripheraledges of the electrically conductive rings. In other words, anelectrically conductive ring is touched by the sawing blade, thusresulting in removal of at least a portion of the periphery of the ringduring the sawing process. This may help to ensure that the electricallyconductive ring extends to the edge of an individual die so that it canbe contacted by material that is (later) plated on the sides of the die.

Next, the separated dies are flipped over in step 70, and then plated(using an E-less plating process) in step 75. The E-less metal platingis applied to the sides and back (i.e. the originally downwardly facingside which is now upwardly facing after flipping) of the dies so that itcontacts at least a portion of the periphery of the conductive ring.

Finally, the dies are removed for testing and/or use in step 80.

Various modifications will be apparent to those skilled in the art. Forexample, the step of etching the die wafer to create sawing guides maybe omitted in alternative embodiments. Also, other embodiments maycomprise the additional steps of thinning and laser marking the wafer,as well as bumping on the top side of the wafer.

In yet further alternative embodiments, the full saw lane etches may bemetal place, so that no individually separated rings are visible priorto sawing the die wafer.

Furthermore, coating the side and lower surfaces of the die with anelectrically conductive shielding material can comprise the step ofspraying metals to apply iso eless plating.

1-6. (canceled)
 7. A wafer level chip scale package, WLCSP, comprising adie having an electrically conductive redistribution layer, RDL, formedabove the upper surface of the die, wherein the electrically conductiveRDL defines a signal routing circuit and forms an electricallyconductive ring surrounding the signal routing circuit, whereinunderlying the electrical conductive RDL, etched trenches in the diesurround the signal routing circuit, and wherein the side and lowersurfaces of the die are coated with an electrically conductive shieldingmaterial such that the electrically conductive shielding materialcontacts at least a portion of the periphery of the conductive ring 8.The WLCSP of claim 7, wherein the electrically conductive shieldingmaterial is an electroless metal.
 9. The WLCSP of claim 8, wherein theelectroless metal is an electroless nickel.